VistaCNC P4-SE pendant stopped working

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7 years 7 months ago - 7 years 7 months ago #129369 by DeckelHead
Yes, that was my intent.... A servo fault would indicate a servo no longer capable of moving, of course, and that is a mode where I want to shut the machine off (estop or machine off seem to have the same net result to me... the relay providing power to the amps will drop out, etc)

OK, good... I think we're onto something. I want to do some more experimenting before I feel comfortable stating that the commenting of the three fault sense signals (X, Y, and Z) directly correlates with the VistaCNC pendant losing sync (BTW, shutting down LinuxCNC and then restarting it re-enables the pendant... I don't need to disconnect it or anything).

I was integrating the fault lines into my HAL as one of the later steps before I mothballed everything last year. It is possible that I didn't detect that the pendant had stopped working last year. My primary focus was on adding the three state lights to my control panel (fault, neg limit, pos limit). As such, I could have been working entirely with the mouse and computer display.

I think my next step will be to (figure out and then) add a pushbutton switch to my UI and reconfigure my HAL so that I can manually "trigger" a fault; this would replace my comparator and sense of the real amplifier output. If that condition results in the pendant going into its lost communication mode, then I think we've nailed the cause of my problem. Sound like a reasonable plan?

Is it possible that my LinuxCNC is corrupted? That seems awfully unlikely in my mind, but does it happen often?[strike] I guess I should look at how one upgrades the application. I doubt (hope) that I need to reinstall the whole image. Getting to the latest released version probably makes sense though[/strike]. Never mind.... I guess I *am* on the latest version! B) B) B)
Last edit: 7 years 7 months ago by DeckelHead.

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7 years 7 months ago #129409 by DeckelHead
This has to be one of the most frustrating problems I've ever diagnosed. Just when you start to think you have something predictable, things start going south, and I have to reset. I'm trying to find a common denominator, and I think I may have one....

I've hatched out a lot of stuff. But even with that, I think that the following behavior should not occur.... Again, using some of the modified HAL files, I can virtually start the system. I say virtual because I really don't have any power going to the servo amplifiers, but the system doesn't know that (my disclosure, in case I'm violating something).

Anyhow, I start LinuxCNC. Then I press and release the pendant estop key over and over again. At this point, I've commented out software interpretation of this switch. It is literally just in the electrical estop chain. OK, so everything works fine.

Then I leave the pendant estop in the released (run) state. After that I toggle the EStop (F1) on the computer.

If I then press the ESTOP key on the pendant, the pendant will timeout and go to the "LinuxCNC" screen again. That seems wrong to me, and it is kind of the minimalist error state I can come up with. Ideas?

A note about my wiring....
My original intent was to have a relay chain that would require me to press a physical (momentary) start button. If there were no open switches in the estop chain, this would allow the estop relay to latch. One of the poles of the ESTOP relay is parallel to the start button, which would allow the relay to remain latched even after the START button was released. I did this for safety. However, it seems like it might be in conflict with the F1 button. Therefore, at the present time, the "start" button has a jumper across it. That means that the ESTOP (F1) on the screen and the physical ESTOP are the only two human controllable "switches" in the estop chain (air pressure and oil level would be other physical one). Because software identification of the pendant estop is presently disabled, the result is that if I press and release the pendant estop relay (while the LinuxCNC estop is in RUN mode), the physical relay will energize and release as a function of the pendant switch state. I don't believe this is pertinent to the problem I'm having but I want to be sure anyone reading this understands how my estop chain is setup. I intend to eventually have a relay drop out because I believe it is safer;

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7 years 7 months ago #129415 by andypugh
How does the pendant interface with HAL?

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7 years 7 months ago - 7 years 7 months ago #129431 by DeckelHead
Good question... In my main INI file (hurco_kmb1-3axis.ini) there are a few new entries:

[HAL]
HALUI = halui
HALFILE = hurco_kmb1-3axis.hal
HALFILE = custom.hal
HALFILE = vc-p4s.hal
POSTGUI_HALFILE = postgui_call_list.hal
POSTGUI_HALFILE = vc-postgui.hal
HALUI = halui
SHUTDOWN = shutdown.hal
........
[HALUI]
MDI_COMMAND=...
MDI_COMMAND=...
MDI_COMMAND=...
MDI_COMMAND=...
MDI_COMMAND=...
MDI_COMMAND=G10 L20 P1 X0
MDI_COMMAND=G10 L20 P1 Y0
MDI_COMMAND=G10 L20 P1 Z0
MDI_COMMAND=G10 X0
MDI_COMMAND=G10 Y0
MDI_COMMAND=G10 Z0


From there, it is standard HAL and INI configuration. Everything was included in the first two posts except for the actual executable driver for the pendant. A better explanation is attached (from VistaCNC, describing the installation process).

I decided to experiment with the simulator I had previously modified to use the VistaCNC pendant. I went through the same process as I did with my real machine, pushing and releasing the estop button multiple times. Everything worked flawlessly. I guess that is good, although it doesn't help me narrow down the cause of the failure.
Last edit: 7 years 7 months ago by DeckelHead.

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7 years 7 months ago #129455 by Mike_Eitel
I have no expirience with usb pendant. But just another approach:
Are you sure that the there is enough usb power. When your activity switch on leds that might give a voltage drop and resets the USB controller.
Mike
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7 years 7 months ago #129472 by JohnnyCNC
I have the same pendant and there are times when it has fits of disconnecting. There are times where I'm pretty sure it is a static electricity issue. When I first installed the pendant I had some of those foam floor mats in front of my mill. If I was holding the pendant and placed a foot on the mat it the pendant would disconnect. I tossed the mats and the problem greatly subsided. Although now I am thinking there may be something to your statement

Are you sure that the there is enough usb power. When your activity switch on leds that might give a voltage drop and resets the USB controller.

. I'm investigating as to whether I can just put additional power across the pos & neg on the usb connector.

John
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